Apparatus for the manufacture of iron and steel



(No Model.) 5 Sheets-Sheet 1.

G'. ADAMS. APPARATUS FOR THE MANUFACTURE OF IRON AND STEEL.

No. 431,863. Patented July 8, 1890.

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(No Model.)

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APPARATUS FOR THE MANUFACTURE OF IRON AND STEEL.

Patented July 8, 1890;

INVENTOR.

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APPARATUS FOR THE MANUFACTURE OF IRON AND STEEL. No. 481,863.

Patented July 8, 1890'.

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0. ADAMS. APPARATUS FOR THE MANUFACTURE OF IRON AND STEEL. No. 431,863.

Patented July 8, 1890.

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WITNESSES.

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Patented July 8, 1890.

0. ADAMS. APPARATUS FOR THE MANUFAGTURE OP IRON AND STEEL.

(No Model.)

D [II w: NORRIS PETERS C0,, PHOT l 0., ASHINGYDN I UNITED STATES PATENT OFFIcE.

CHARLES ADAMS, OF ST. LOUIS, MISSOURI, ASSIGNOR OF ONE-HALF TO RALPH \V. CARROLL AND FERDINAND PROTZMAN, SR., BOTH OF PITTS- BURG, PENNSYLVANIA.

APPARATULS F OR THE MANUFACTURE OF IRON AND STEEL.

SPECIFICATION forming part of Letters Patent No. 431,863, dated July 8, 1890.

I Application filed September 3, 1889. Serial No. 322,813. (No model.)

To all whom it may concern.-

Be itknown that I, CHARLES ADAMS, a citizen of the United States, residing at St. Louis, in the State of Missouri, have invented or discovereda certain newand useful Improvement in Apparatus for the Manufacture of Iron and Steel, of which improvement the following is a specification.

My improvement consists in an apparatus adapted for the manufacture of iron and steel by continuous process direct from the ore, in which the ore is to be subjected tothe action ofa reducing or carbonizing atmosphere, and thereby converted into sponge, and then conducted directly to an open-hearth furnace for conversion into steel, and in certain details of construction hereinafter more particularly described.

To enable others skilled in the art to construct and use my improved apparatus, I will proceed to describe its construction, arrangement, and in connection therewith explain its operation as applied to the manufacture of iron and steel.

The accompanying drawings, illustrating my invention, consist of five sheets, each containing one figure.

Figure 1 is a vertical representation of my improved furnace, partly in section. Fig. 2 is a sectional elevation of my improved furnace on the dotted line II II of Figs. 1 and 3. Fig. 3 is a horizontal plan and section on the line III III of Fig. 2. Fig. 4; is a side elevation of the furnace, showing its connection with an open-hearth furnace, the latter being in section. Fig. 5 represents a modification of my apparatus.

Like letters of reference denote the same parts of the apparatus in each of the figures.

A is the furnace, built of brick-work upon a foundation B, which, as shown in the drawings, is rectangular and oblong, but may be circular, elliptical, or other convenientshape. Suitable proportionate dimensions are a length of ten times its width and a height which will allow of the sufficient subjection of the ore to the reducing atmosphere--say ten to fifteen times its width. These relative proportions, however, are not of the essence of the invention and are given merely as a statement of proportional size which has been found successful in practice. The interior of the furnace is furnished with checkerworkC O of fire-brick, arranged on each side and at the two ends of the furnace, as shown in Figs. 2 and 3, the checker-work O O being so arranged, as shown in those figures, to leave a clear vertical space D from the top to the bottom of the furnace. In this space D the ore is charged and is reduced. The space D is long and narrow, as shown in Fig. 3, and tapers upward in width, being narrower at top than at bottom, so as to give the neces sary clearance for the descent of the charge. 'Ihisworking-space D is closed at top by a covered hopper E, which has, besides its cover at the bottom of the hopper, a hinged trapdoor e for the admission of the charge, which is normally kept closed by a Weight w. The working-space D is also closed at the bottom either by a removable door of ordinary construction or, preferably, as shown in the drawings, Fig. 2, by being placed over a tightly-closed reservoir F, which forms part of the foundation B. This reservoirF is the receptacle into which the reduced ore (iron sponge) is discharged from the working-space D of the furnace, and is provided with one or more inclined chutes G, from which the reduced ore is removed from time to time, dou- 8o ble sliding doors 1) I) being provided to each chute, so that one may be closed when the other is open, so as practically to exclude the air from contact with the hot sponge.

The checker-work O O, &c., in the interior of the furnace A is placed within a series of separate chambers formed by the horizontal shelves or diaphragms H H, &c., which exitend from end to end of the furnace and from.

each side to the'central working-space D; but

the diaphragms II 011 one side of the space D are not on the same level as those H on the opposite side, (see Fig. 2,) the diaphragm II on one side being placed in a horizontal plane about midway between two diaphragms II on 9 5 the opposite side.

Below the furnace A are placed two regenerators K K, fitted with brick checker-work L in the usual way; These regcnerators are connected by uptakes M with a horizontal flue N, which extends the whole length of the furnace and connects by numerous adits n with the checker-work O in the lowest checker-work chamber of the furnace on one side, as shown in Fig. 2. Valves P P (preferably made of fire-clay tile) are connected with the flue N, by which the regenerators K K are alternately connected with the checker-work O in the lowest chamber in the interior of the furnace. A short horizontal flue R connects the topmost of the checker-work chambers C of the furnace with a downtake or draft-fine Q, which conveys the gas as it leaves the furnace downward to one of the regenerators K K through the butterfly-valve S, which can be set so as to admit the gas from the top of the furnace into either of the regenerators, the valves 1, P, and S being rcversed from time to time, so that when the regenerator K is in connection with the furnace the other regenerator K is connected with the downtake-flue Q, and vice versa. A steam-ejector T, placed in the downtake Q, determines the direction of the draft clownward from the top of the furnace A to the regenerators and regulates its amount and velocity. A flue U connects both of the regenerators K K with a stack or chimney to carry off the products of combustion, and a valve it, according as it is set, connects .one or other of the regenerators with the flueor chimney.

The reducing-gas by which the ore is to be reduced may be either carbonic-oxide (CO) or hydrocarbon gas or vapor, which is prepared in a separate gas-producer of any desired construction. If carbonic oxide is used, the common Siemens gas-producer may be employed; if hydrocarbon gas or vapor, it may be manufactured in any suitable apparatus, or may be simply a vessel charged with petroleum or other liquid hydrocarbon and heated sufficiently to vaporize it. v

V is a valve for admitting the carbonicoxide or hydrocarbon gas or vapor from the producer to one or other of the regenerators K or K, according as the valve V is set.

The spout of the chute G may be extended by a movable spout g, as shown in Fig. 4, so as to conduct the hot sponge or reduced ore directly from the reservoir F into the openhearth furnace WV, previously provided with a charge of molten-bath metal. The openhearth furnace V, being of any ordinary construction of such apparatus and well known to those skilled in the art, needs no further description here. I

In case it is desired to dispense with the use of the regenerators K K, a simpler construction of my furnace may be used, as shown in Fig. 3.

The furnace itself, with the workingspace D, partitions H ll, and checker-work O O,

placed in separate chambers, is the same as already described; but in place of the regenerators K K, their flues and valves, and fiue N and openings 21,1 place underneath the furnace a pair of fire-places X X, in which solidcarbonaceous fuel is consumed by slow combustion, so as to produce carbonic oxide, which is introduced into the lowest checkerwork chamber G through a flue c. In this case the downtake Q is furnished with the ejector T, and the escaping gas from the top of the furnace is conducted under the steamboiler to serve as fuel; or, if preferred, by closing the valves Y and opening the valve Y the gas will pass off to the stack or through the pipe Z to be used for any purpose that may be desired.

The operation of the apparatus hereinbefore described as applied to the reduction of iron ores and the manufacture therefrom by a direct and continuous process is as follows: When the furnace is first used, or when first used after having been emptied of its charge,

the reservoir F may be filled up to the bottom of the working-space D with ore, coke,

use for this purpose coke to the amount of ten to fifteen per cent, by weight, of the charge of ore. The working-space D is filled with this charge from top to bottom, and if a continuous process is desired the working-space is kept filled up with ore (or ore and carbon) as the reduced ore gradually passes away below. Before commencing the operation of reduction the regenerators K K are both heated to from 800 to 1,200 Fahrenheit. The supplypipe of the ejector T is con nected with the live-steam space of a steamgenerator, the hopper E is closed, as also the sliding doors I) Z) in the chute of the reservoir F, so as to exclude as much as possible the external atmospheric air from the interior of the furnace A, and the valves S, P, and V are set so as to connect one regenerator, as K, with the flue N, and thus with the lower chamber 0 of one side of the furnace A. The valve is set so as to connect the same regenerator K with the gas-producer, and the valve S is set so as to connect the downtake Q from the top of the furnace with the other regenerator K. The apparatus being thus adjusted, the carbonic-oxide gas from the gas-producer enters the flue, and thence passes up through previously-heated checker-work in the regenerator K and becomes thereby heated to a temperature of from 800to 1,200 Fahrenheit, and thence arises through the uptake M into the flue N and enters the lowest checkerwork chamber C at one side of the furnace through the adit n, heating the checkerwork in the furnace as it traverses it. As the gas finds no passage-way upward, being obstructed by the partition or diaphragm II, it passes sidewise with the mixed ore and carbonaceous matter at the lower end of the working-space D. Here, its upward passage through the superincumbent charge of ore being difficult, the gas, following the path of least resistance, enters the lowest of the chambers C on the opposite side of the furnace. Here it rises through the checker-work until it meets the obstruction of the first partition of that side of the furnace, which is at a higher level than the first partition on the other side, and is forced to pass again sidewise into the charge of ore, 850., in the working-chamber D,

and, again taking the path of least resistance, it enters the checker-work on the side of the furnace at which it first entered, but into a chamber higher up, and thus, owing to the obstruction presented by the partitions H H, &c., on one side and H H on the other side, and to the position of the partitions on one side of the space D being on a different level from those on the opposite side, the reducinggas is compelled to follow a zigzag course backward and forward through the column of ore in the working-space D until it reaches the horizontal flue B, through which it enters the downtake Q and passes down through the valve S, set to conduct it into the other regenerator K. Here the gas meets and combines with a current of atmospheric air admitted in any desired and regulated quantity to secure complete combustion by means of the valve WV communicating its heat to the checker-work in the regenerator. The products of combustion thence pass off through one of the flues U and valve 10 to the stack or chimney placed at any convenient point. The downward draft through the downtake Q, and consequently the upward current through the furnace A, is secured and regulated by the ejector T, situate in the downtake Q.

In order to preserve the required uniform temperature of gas passing through the furnace, the regenerator-valves should be shifted every ten or fifteen minutes, so as turn the supply-gas from the producer into the regenerator, which has just been heated up by combustion of the escape-gas from the top of the furnace, and thence through the valve? and flue N into the bottom of the furnace, and to change the course of the escape-gas from the top of the furnace through the downtake Q by the valve S into the regenerator through which the supply-gas has just been passing.

The reactions produced by the use of my improved apparatus, as above described, are as follows: The heated reducing-gas (carbonic oxide) passing through the body of the ore in the working-space D of the furnace eifects the deoxidation of the ore. The oxygen liberated from the ore has a tendency to combine with the carbonic oxide (00) and form carbonic acid, (C0 the presence of which would arrest the deoxidation of the ore; but this tendency is counteracted partly by the carbon when used mixed with the charge of ore, but chiefly by the constant access from the gas-producer or source of supply to the interior of the f urnacc of fresh carbonic-oxide or hydrocarbon gas or vapor preheated by passage through one of the regenerators and by the heat of the furnace,'which is such that carbonic acid cannot exist in the presence of carbon. Furthermore, the desired degree and uniformity of temperature of the reducing-gas is maintained within the fun nace by the heat communicated to and'stored up by the checker-work in the several chambers of the furnace, which absorb and take up any excess of heat of the incoming gas which may occur, as in case of the reversal of the valves turning the gas through a freshly-heated regenerator, and give out this stored-up heat to the when its temperature is reduced by the cooling of the regenerator previous to such reversal, and thus by means of the use of the apparatus herein de scribed the reducing quality of the gas as well as the necessary uniform degree of heat is maintained throughout the furnace and during its entire operation.

The result so far as described is the production of deoxidizediron ore, properly called iron sponge. As this is formed without fusion, the pieces do not adhere together, but preserve very nearly the size and shape of the pieces of ore charged into the top of the furnace. In consequence of the reducing-gas passing back and forth through the charge of ore repeatedly before it escapes at the top of the furnace and being unable to rise up directly through the charge, the ore is much more thoroughly treated than it can be in any other apparatus of which I have any knowledge, and as the gas after each passage across the working-space through the ore is compelled to enter the checker-work before returning through the ore its temperature is regulated and rendered uniform, as hereinbefore explained. The iron sponge thus pro duced drops down gradually into the recep tacle or reservoir F, which, extending under the entire length of the furnace, will hold a large amount of sponge. The doors 1) Z) being kept closed, the sponge is substantially protected from the access of external atmospheric air, which would rapidly oxidize the sponge, especially when in a heated condition.

In order to effect the conversion of the iron sponge into steel, I place an open-hearth f or nace WV, Fig. 4, sufiicientlynear to the reservoi r F, so that the hot sponge may be conveyed by a movable spout 9, connected with the chute G, into a prepared bath of molten carbide of iron in the open hearth. It is proper to state in this connection that in the use of my apparatus the supply of atmospheric air to the open hearth should be turned off during the time that the hot sponge is being introduced in order that it may not be exposed to the action of an oxidizing atmosphere, and that the mode of using the open-hearth furnace is the same as ordinary, excepting that less time is required for melting the sponge than for melting the ordinary Wrought-iron additions in the bath.

In using my improved apparatus for the manufacture of iron or steel carbureted-hydrogen gas or hydrocarbon vapor may be employed as the reducing agent, in which case a smaller proportion of solid carbon, or sometimes none at all, needs to be mixed with the. charge of ore, the operation of my improved apparatus being the same in eithercase as to the deoxidizing of the ore and preservation of the desired uniformity of character and temperature of the reducing agent due to the described construction of the reducing apparatus.

In case the furnace is used without the regenerators, as shown in Fig. 5, the combustion of the carbonaceous fuel in the furnaces is conducted with a limited supply of air, so as to produce carbonic oxide rather than carbureted hydrogen and fuliginous matter. The apparatus thus constructed is simpler and cheaper than that shown in the other figures and can be used to great advantage; but it is more difficult to preserve a uniform heat or a uniform quantity and quality of the reducing-gas, because every time the fire is stirred or fresh fuel is added to it more fuliginous matter is evolved and the production of carbonic oxide is decreased.

My improved apparatus is capable of use to great advantage for other purposes than the manufacture of iron and steelas, for example, for the manufacture of coke and charcoal and by-products therefrom-and I desire to cover by this patent the use of said apparatus for such purposes.

I have described my improved furnace as vertical and having a vertical Working-space and arranged with checker-Work so disposed that the reducing-gas must pass upward and across through the charge, because I believe this to be the best arrangement; butI desire not to limit my invention, either as to process or apparatus, to such vertical arrangement and upward movement of the gas, as it is quite possible to accomplish similar results with a horizontal or inclined furnace and a. forced draft.

I do not herein claim the process of manufacture of iron and steel herein described, as I purpose filing a separate application therefor; but

What I claim as my invention, and desire to secure by Letters Patent, is

1. A furnace for reducing oxide of-iron, consisting of an outside shell divided internally by horizontal partitions into separate heat-chambers exterior to and on opposite sides of a central space for the reception of ore, the partitions being located at different levels on opposite sides of the furnace, connected at the lower end with apparatus for supplying reducing-gas and with an opening for the discharge of reduced ore, and at the upper end with a charging-hopper and exitflue for the escape of the waste gas, the chargin g and discharging openings being provided with devices for the exclusion of the external atmosphere, substantially as described.

2. The combination, with a pair of checkerwork regenerators and a source of supply of reducing-gas and suitable reversing valves and pipes, of a furnace containing checker- Work surrounding aworking-space for reception of the charge, said checker-work being divided inside the furnace by imperforate partitions into separate chambers, with charging and discharging apertures provided with devices for the exclusion of the external atmosphere, substantially as and for the purpose described.

3. The combination, as a plant for the manufacture of iron and steel by a continuous process direct from the ore, of the following elements, viz: an open-hearth furnace of any suitable construction, a furnace for the continuous deoxidation of iron ore containing checker-work around a central Working-space divided into separate chambers by imperfo rate partitions, a pair of reversible regenerators of checker-work, with their necessary reversing valves and pipes for heating the gas supplied to the furnace, and a source of supply of reducing-gas, constructed and arranged substantially as hereinbefore described.

In testimony whereof I have hereunto set my hand.

CHARLES ADAMS.

Vvitnessesz W. B. CORWIN, J. K. SMITH. 

